Methods for lightweight design of mechanical components in humanoid robots

With the development of humanoid robots, lightweight construction and energy efficiency play an important role as these mobile, dynamic systems have to work self-sufficiently. The application of computer-aided (CAE) methods in the development process is one possibility to achieve the required weight reduction. On the basis of a classical topology optimization carried out on the robot ARMAR III, an extended system-based method for dynamic, mechatronic systems is presented. Different analysis domains, namely hybrid multibody system dynamics (MBS), finite element analysis (FEA), control system simulation and topology optimization are integrated into a straightforward, automatic way. For the use of fiber reinforced composite materials in such parts, a FE-based method for the determination of ply orientations and thickness relations is presented.